RCM GUIDE RELIABILITY-CENTERED MAINTENANCE GUIDE For Facilities and Collateral Equipment DRAFT FINAL National Aeronautics and Space Administration September 2008 NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT TABLE OF CONTENTS 1.0 Preface .......................................................................................1-1 1.1 RCM and NASA .............................................................................. 1-1 1.2 Applicability and Use of this Guide ..................................................... 1-4 2.0 Historical Evolution of Reliability-Centered Maintenance.........................2-1 2.1 Preventive Maintenance .................................................................. 2-1 2.2 Condition-Based Monitoring .............................................................. 2-3 2.3 Reliability-Centered Maintenance....................................................... 2-3 3.0 The RCM Approach .........................................................................3-1 3.1 Introduction to Reliability-Centered Maintenance ................................... 3-1 3.2 Types of RCM ............................................................................... 3-2 3.3 RCM Principles.............................................................................. 3-4 3.4 RCM Analysis ................................................................................ 3-7 3.5 Benefits of RCM ............................................................................ 3-9 3.6 Impact of RCM on the Facilities Life-Cycle .......................................... 3-11 4.0 RCM and Failure Analysis .................................................................4-1 4.1 Failure ....................................................................................... 4-1 4.2 Failure Modes and Effects Analysis...................................................... 4-9 5.0 RCM Program Components ...............................................................5-1 5.1 Reactive Maintenance..................................................................... 5-3 5.2 Preventive Maintenance .................................................................. 5-4 5.3 Predictive Testing and Inspection....................................................... 5-7 5.4 Proactive Maintenance.................................................................... 5-9 5.5 Acceptance Testing...................................................................... 5-11 6.0 Predictive Testing and Inspection Technologies.....................................6-1 6.1 Introduction................................................................................. 6-1 6.2 Alerts and Alarms .......................................................................... 6-1 6.3 Vibration Monitoring and Analysis....................................................... 6-3 6.4 Infrared Thermography ................................................................... 6-6 6.5 Ultrasonic Noise Detection ............................................................... 6-9 6.6 Lubricant and Wear Particle Analysis................................................. 6-12 6.7 Electrical Condition Monitoring........................................................ 6-22 September 2008 i NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT 6.8 Non-Destructive Testing ................................................................ 6-31 6.9 Photography .............................................................................. 6-42 7.0 Predictive Testing and Inspection Criteria............................................7-1 7.1 Baselines .................................................................................... 7-1 7.2 Criteria by PT&I Technology ............................................................. 7-1 8.0 RCM Requirements During Facilities Acquisition ....................................8-1 8.1 Planning ..................................................................................... 8-1 8.2 Predesign.................................................................................... 8-1 8.3 Design........................................................................................ 8-1 8.4 Construction ................................................................................ 8-3 8.5 Maintenance and Operations............................................................. 8-5 9.0 RCM Considerations During Facilities Operation.....................................9-1 9.1 RCM Program Data ......................................................................... 9-1 9.2 Maintenance Feedback.................................................................... 9-8 9.3 Maintenance and Operations Considerations .......................................... 9-8 10.0 RCM Contract Clauses.................................................................. 10-1 10.1 General Contract Clauses ............................................................. 10-1 10.2 Architect and Engineering Contracts ............................................... 10-18 10.3 Construction Contracts ............................................................... 10-19 10.4 Equipment Procurement Contracts ................................................. 10-21 10.5 Maintenance and Operations Contracts............................................ 10-23 11.0 Checklists for RCM Quality Assurance .............................................. 11-1 11.1 Planning.................................................................................. 11-1 11.2 Design .................................................................................... 11-2 11.3 Construction............................................................................. 11-3 11.4 Equipment Procurement .............................................................. 11-4 11.5 Maintenance and Operations ......................................................... 11-5 12.0 Key Performance Indicators.......................................................... 12-1 12.1 General................................................................................... 12-1 12.2 Purposes of Key Performance Indicators ........................................... 12-2 12.3 Sample KPIs.............................................................................. 12-3 12.4 Trending Indicators..................................................................... 12-4 ii September 2008 NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT 12.5 Metric Selection ........................................................................ 12-5 12.6 Benchmarking Background ............................................................ 12-5 12.7 Benchmark Section ..................................................................... 12-6 12.8 Utilization of KPIs ...................................................................... 12-7 12.9 Examples of Benchmarks .............................................................. 12-7 12.10 Planning and Scheduling KPIs ....................................................... 12-9 12.11 RCM KPIs............................................................................... 12-10 13.0 Building Commissioning ............................................................... 13-1 13.1 Building Commissioning Overview ................................................... 13-1 13.2 Types of Commissioning ............................................................... 13-1 13.3 Commissioning Goals................................................................... 13-4 13.4 Commissioning and Sustainability.................................................... 13-6 13.5 The Commissioning Team ............................................................. 13-7 13.6 The Commissioning Process........................................................... 13-7 14.0 Maintainability .......................................................................... 14-1 14.1 Introduction ............................................................................. 14-1 14.2 Summary ................................................................................. 14-3 14.3 Maintainability, Reliability, and Availability ....................................... 14-4 14.4 Theory of Maintainability ............................................................. 14-6 14.5 Background .............................................................................. 14-8 14.6 Maintainability at Other Federal Agencies ......................................... 14-9 14.7 First Principles of Maintainability Design .......................................... 14-11 14.8 Review for Design Maintainability Considerations................................ 14-14 14.9 Replacement and Modularity Design Requirements.............................. 14-20 14.10 Fault Detection and Isolation Design Requirements............................ 14-20 September 2008 iii NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT LIST OF FIGURES Figure 2-1. Bearing Life Scatter .........................................................................2-2 Figure 3-1. Components of an RCM Program ..........................................................3-1 Figure 3-2. NASA RCM Logic Tree........................................................................3-5 Figure 3-3. RCM Analysis Considerations ...............................................................3-8 Figure 3-4. Effect on